Combination roofing-sheathing panel system



United States ABSTRACT OF THE DISCLOSURE A system of weatherproofplywood panels provided with decorative facings of wood shakes, shinglesor the like, the system combining the functions of roof sheathing androofing to permit rapid installation by relatively unskilled labor overconventional roof framing to produce a decorative roof.

The present invention is concerned with a high quality 9 decorative roofsystem consisting of a combination of waterproofed plywood panels andshakes, shingles, or other suitable decorative facings. The systemcomprises essentially a series of plywood panels with a durablewaterproof overlay and decorative facing which are applied to suitablestudding or rafters in overlapping fashion. The panels areself-supporting and are aifixed directly to the roof framing without therequirement of conventional roof sheathing. Nailing may be concealedunder the lap of the subsequent course above. The action of the nailsthus applied is such as to place a leverage on the roofing panel to holdthe lower portion down securely against the previous course afiixedbelow.

The panels are installed so as to provide slightly more than doublecoverage; that is, the roof is covered at all places with at least twolayers of the weatherproof plywood panels. The ends of the panels arealternated in each successive course so that the open joint betweenneighboring panels is always backed up by the waterproof surface of theprevious course beneath. End joints need not occur over the structuralframing elements, since the overlapping nature of the installationprovides adequate reinforcement wherever such joints might fall. Adecorative facing such as shakes, shingles, tiles, slates, aggregate,granules, thatch, etc. is aflixed to the exposed portions of the plywoodpanels in manufacture. This decorative facing need not perform thefunction of excluding water and the weather since the supporting panelbeneath is completely waterproof. Thus, the decorative element may be ofa discontinuous nature, of low grade and/ or with open defects.

The present invention may be fully understood by reference to thedrawings illustrating adaptations of the same. FIG. 1 is a side viewshowing the overlapping and the interrelationship of respective panelswith decorative shake facing. FIG. 2 is a top view illustrating in somedetail a single panel with the waterproof overlay and decorative shakes.FIG. 3 is a perspective view showing the application of the panels to aconventional roof structure, while FIG. 4 illustrates a single panelwith overextending shake facing.

Referring specifically to FIG. 1, a rafter or roof truss illustrates aseries of similar rafters which are suitably supported by means oflumber plates and upright studding which also represents a series ofupright studs. In application, a starter strip 9 along with a starterpanel 1 is affixed to rafter 10 at the end thereof by means of a nail21. It is to be noted that the lower edge of starter panel issubstantially flush with starter strip 9. A first full panel 3 withdecorative shakes 2 attached as illustrated, is positioned so that thelower edge of the plyice wood base is also substantially flush with theedge of starter strip 9 which permits the shake to overextend thefascia. Panel 3 is affixed to rafter 10 by means of nail 22 atsubstantially its midway point or imaginary center line located midwaybetween the upper and lower edges of the base panel 3 in a manner thatnail 22 passes through the upper edge of starter panel 1. Thus, there isa leverage exerted by panel 3 along the entire area of starter panel 1.

A second full panel 5 is abutted to the tips of the decorative shakes 2of panel 3 and affixed to rafter 10 at its substantial midpoint orimaginary center line by means of nail 23 in a manner that the nail alsopasses through the upper edge of panel 3. Here again, a leverage isexerted by panel 5 along the upper area of panel 3. A third full panel 7is then abutted to the tips of shakes 4 of panel 5 and afiixed to rafter10 by means of nail 24 in a manner that the nail passes through theupper edge of panel 5. The fastening nails, such as, 22, 23, and 24, donot pass through the decorative elements of shakes, slate, tile, orother decorative covering elements.

Referring specifically to FIG. 2, one satisfactory set of desireddimensions is illustrated. A waterproof overlay 31 is afiixed over theentire face of panel 32. This overlay may comprise any suitableWeatherproof material such as 5S-lb. asphalt-impregnated roofing feltand any satisfactory adhesive may be used for bonding the overlay,although the overlay need not be bonded in all cases if staples or othermeans are used to secure it in place. It is to be noted in this detailthat the shakes overlap the plywood base panel approximately two inches.

Referring specifically to FIG. 3, the panels applied in overlappingfashion are affixed to rafters 10 with end joints staggered.

Referring specifically to FIG. 4, one particular configuration which issatisfactory consists of /3" x 16" x 96" exterior plywood panel to whicha 55-lb. roofing felt is laminated using suitable adhesive. The 17%"wide felt preferably extends about 1%" over the drip edge of the plywoodpanels. Special sized Western Red Cedar shakes of 9" length are thenfastened over the felt with /4 crown, 1" long, divergent point,galvanized steel stapes approximately 3" o.c. so that the butt endsextend about 2" over the drip edge.

The manner of installing roofing panels is to tack a thick starter stripat the cave. Then position the starter panels with plywood edges alignedto the starter strips and nail through the panels and starter stripsinto each rafter using preferably 2 /2" galvanized asphalt roofingnails. The roofing panels are positioned so that the plywood edge alignswith that of the starter strip and starter panel and staggering thejoints with the starter panels, roofing panels are nailed at each rafterat approximately their midpoint with the 2 /2 roofing nails. Thesubsequent courses are positioned in overlapping fashion so that theplywood edge butts up to the tip of the shakes on the previous courseand staggering the joints with the previous panels. The roofing panelsshould overhang approximately 1 at the rake edge.

The installation results in small triangular open spaces at the rakeedge of the roof at the gable ends. These spaces may be filled in withsmall wedge-shaped pieces of wood (approximately 2" wide X at the thickend and of suitable length) to produce a flat, pleasing appearance onthe underside of the overhang.

The last course is affixed so that the shake tips reach as close aspossible to the ridge peak and the surface is cut off. The ridge iscapped with flashing and subsequently covered with individual shakes inthe conventional manner. As to hips, the panels are cut to theappropriate angle and fitted tightly; triangular pieces of flashing areinterwoven as the courses are laid up and the hip is subsequentlycovered with individual shakes in the conventional manner. As to thevalleys, blocking is provided to at least 3" from the valley center whenframing the roof. In laying up the roof, the panels are cut to theappropriate angle at valley and fitted tightly to form a closed valley.Approximately x 20" squares of flashing are interwoven with each courseand the roofing panels are nailed at least 2 /2" in from the valleycenter.

Although the foregoing has emphasized a decorative facing of shakes, itshould be noted that the split shakes may be replaced with otherdecorative facings such as slate, tile, mineral granules, aggregate,thatch and the like. Such decorative facings may be aflixed by anysuitable permanent means, including nails, staples, adhesive, mastic,and other fastening devices.

Thus, the present invention is concerned with a unique combined roofingand sheathing single panel which is adapted for rapid and efficientapplication direct to the roof framing with a minimum of skill. Thepresent invention provides a system which will accommodate to any detailnormally encountered in covering a roof which includes the flashing atchimneys, the vents, the valleys, details for hips, ridges, eaves, andrakes. Also the overlapping plywood base with weatherproof overlayperforms the actual function of excluding the elements, while thevisible portion of the panel may be manufactured wtih any number ofconventional or unconventional facing materials to provide the desiredesthetic effect. Limited use of the normally expensive decorativeelements substantially reduces cost and in the case of materials such astile or slate, also materially reduces the weight which otherwise wouldrequire heavier structural framing to support the load.

The large proportionate overlap of the plywood base panels is veryimportant in that it precludes the necessity for the use of shims,strips, caulk, and the like or any other special treatment at the endjoints because it provides a weatherproof back-up at these jointswherever they occur. The panels may be cut to any length necessary onthe site with a simple straight cut. Thus, the resulting pieces may beused without special attention to the cut ends. In addition, thesubstantial degree of lap permits the use of thin plywood panels sincethe installation described results in at least two layers at any pointon the roof. This reinforcing elfect also permits random location of endjoints, since they do not require support of the structural framingbeneath. The double coursing of plywood base also simplifies flashingdetails in that it provides continuous support for the flashing pieceswhich extend up under the lap. The present invention represents adistinct advance over the art since several functions are combined intoone piece and into larger panels which are self-aligning with nocomplicated installation details.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:

1. Weatherproof and decorative structure which comprises a plurality ofweatherproof base panels aflixed to supporting means in overlappingfashion as a first course of base panels and succeeding courses of basepanels, said base panels having upper edges and lower edges, incombination with decorative elements affixed to the top surfaces of saidbase panels in manufacture, said decorative elements being affixed in amanner that the lower edges of said decorative elements over-extend thelower edges of said base panels and that the upper edges of saiddecorative elements under-extend the upper edges of said base panels,said base panels having imaginary center lines located substantiallymidway between said upper edges and said lower edges of said base panelsand extending parallel to said edges, said base panels being affixed tosaid supporting means by nails passing through said basepanels at pointssubstantially along said center lines, said nails spaced from an edge ofthe decorative element and out of contact therewith, and said structurecharacterized in that the lower edges of said base panels in asucceeding course abut against the upper edges of a decorative elementin a preceding course and that the lower edges of decorative elements insaid succeeding course overlap the upper edges of decorative elements ofsaid preceding course.

2. Structure as defined by claim 1 wherein said panels are laminatedplywood panels.

3. Structure as defined by claim 2 wherein said structure comprises aroof covering. a

4. Structure as defined by claim 2 wherein said structure comprises asidewall covering.

5. Structure as defined by claim 2 wherein said decorative elementcomprises wooden shakes.

6. Structure as defined by claim 2 wherein said decorative elementscomprise cedar shingles.

7. Structure as defined by claim 2 wherein said decorative elementscomprise mineral granule decorative, weather-resistant facings aflixedto the functional plywood base panels during manufacture.

8. Decorative structure as defined by claim 1 wherein said base panelsare plywood panels of about 8 feet long and wherein the distancesbetween said upper edges and said lower edges of said base panels areabout 16 inches.

9. Structure as defined by claim 8 wherein the upper edges of saiddecorative elements overextend the lower edges of said base panels byabout 7 inches and the lower edges of said decorative elementsover-extend the lower edges of said base panels by about 2 inches.

10. Structure as defined by claim 9 wherein waterproof materials arebonded to the upper surfaces of said base panels.

11. Structure as defined by claim 10 wherein said waterproof materialsare roofing felts which over-extend the lower edges of said base panelsby about 1 inches.

12. Structure as defined by claim 1 wherein waterproof membranes areaffixed to the top surfaces of said base panels, characterized in thatsaid membranes have overextensions which extend beyond the lower edgesof said base panels, said overextensions being positioned between thelower edges of said base panels and the upper edges of said decorativeelements.

References Cited UNITED STATES PATENTS 1,549,263 8/1925 Johnston f 525572,110,579 3/1938 Robinson 52556X 2,232,786 2/1941 Kendall 52557X2,513,977 7/1950 Wells 52557X 3,440,770 4/1969 Martin 52560X PRICE C.FAW, 111., PrimaryExaminer US. Cl. X.R.

